Rfid-enabled electrical connector

ABSTRACT

The present invention is an RFID-enabled electrical connector with connector position assurance (“CPA”) features. The RFID tag is only readable after the CPA features have been fully deployed. The electrical connector is comprised of at least two parts, a socket and a plug. In the illustrated embodiment, a connector housing is positioned between the socket and plug, with both the socket and plug connecting to the connector housing. Until the CPA feature has been fully deployed, the RFID tag is covered by an electrically conductive material, preferably an electrically conductive plastic. The RFID tag can only be properly read after the CPA feature has been fully deployed. To prevent signal leakage, the RFID tag can alternately be placed inside a five-sided box fabricated from electrically conductive material, preferably electrically conductive plastic.

FIELD OF INVENTION

This invention relates to the classification of electrically-conductiveconnections, and to one or more sub-classifications under means forpreventing, inhibiting, or avoiding incorrect coupling. Specifically,this invention is a push-in electrical connector secured by an interiorspring mechanism.

BACKGROUND OF INVENTION

Over the past several decades, the amount of electronics in in motorvehicles has increased substantially. Electronics are used to improveperformance, control emissions, and provide creature comforts to theoccupants and users of the motor vehicles. Motor vehicles are achallenging electrical environment due to vibration, heat, andlongevity. Heat, vibration, and aging can all lead to connector failure.In fact, loose connectors, both in the assembly plant and in the field,are one of the largest failure modes for motor vehicles. Consideringthat just the aggregate annual accrual for warranty by all of theautomotive manufacturers and their direct suppliers is estimated atbetween $50 billion and $150 billion, worldwide, a large failure mode inautomotive is associated with a large dollar amount.

The category with the highest warranty and quality cost in automotiveindustry are electrical connections, specifically mis-seated electricalconnections. These warranty problems are caused by an incompleteconnector mating process at the vehicle assembly lines, as there are noreliable methods to assure and record/verify that an electricalconnector is fully mated.

Connector design has evolved numerous features in order to address thisissue. One of the most common features is Connector Position Assurance(“CPA”). A CPA feature is a secondary lock that cannot be engaged untilthe connector is fully seated. CPA features have not resolved theoverall warranty problems, because there is no contemporaneous method,measurement, or record proving that the CPA feature is being properlyinstalled and deployed.

Another large source of warranty related to electrical connectors inautomotive involves high-power connections to alternators, batteries,power, and power junction boxes. With hybrid engines, there are evenmore high-power connections. The most common solution for this type ofconnection is the eyelet. An eyelet is a metal fitting requiring athread fastener and nut. Although eyelets are specified as requiring acertain torque and angle during installation, there is no method,measurement, or record to prove the eyelet is being properly installedand deployed. Eyelets are being displaced because of the substantialcost of installation and the cost of warranty.

High-power/high-voltage (“HP/HV”) connectors with spring-loadedactuators are displacing eyelets. There is a demand that the new HP/HVconnector designs yield recordable proof that they have been correctlyinstalled. Such records do not currently exist.

The industry currently uses sub-standard solutions for recordinginstallation. For example, barcodes are used with CPA features. Thebarcode is placed in a position in which it can only be read when theCPA is fully seated. Unfortunately, this method only works if an openarea exists around the CPA, so that a barcode reader can access thebarcode. In most of cases such space is not available and this method isnot complete solution for connector assembly process. Moreover, thismethod of error-proofing is expensive, as an employee is usually used toread the bar-code

The automotive market has a need for a method that records that eachelectrical connector has been properly installed. The method should bequick, inexpensive, and error-proofed. No such solution exists today.

SUMMARY OF THE INVENTION

This summary is intended to disclose the present invention, anRFID-enabled Electrical Connector. The embodiments and descriptions areused to illustrate the invention and its utility, and are not intendedto limit the invention or its use. In the illustrated embodiment, theRFID-enabled Electrical Connector is embedded in a CPA feature.

RFID, or radio-frequency identification, uses electromagnetic fieldsgenerated by an RFID reader to automatically identify an object with anRFID tag. An RFID tag consists of a miniature radio transmitter andreceiver on which is stored a unique string of digital data. The RFIDreader transmits a digital pulse which causes the RFID tag to transmitits string of digital data in response. This string of digital data isusually interpreted as an inventory control number, serial number, orother unique alphanumeric code. An RFID tag can be either passive oractive. A passive RFID tag is momentarily energized by the pulse fromthe RFID reader, causing the passive RFID tag to transmit its string ofdigital data. An active RFID tag is powered by an onboard battery, whichwill give it superior transmission range. Unlike a barcode, an RFID tagdoesn't need to be within the line of sight of the reader, so it may beembedded in a tracked object.

An electrical connector will typically have a plug or male portion and asocket or female portion. In connectors with a CPA feature, the CPAfeature is typically included in the socket. The plug is first fullyinserted into the socket, engaging the CPA feature. This usually createsan initial “click” indicating that the housing of the plug has engagedan inbound connector tab on the CPA feature of the socket. When theinbound connector tab engages, it enables an outbound connector tab. Theplug of the connector is then partially pulled out of the socket of theconnector, creating a second “click” indicating that the outboundconnector tab has locked the plug into position with respect to thesocket.

This invention uses an RFID tag in combination with a CPA feature. Whenthe RFID tag is covered by the conductive material, it is shielded. Whenthe RFID is shielded by the conductive material, the RFID reader cannotenergize the RFID tag, because the RFID signal cannot reach the RFIDantenna. When the RFID-enabled Electrical Connector is improperlyinstalled, the CPA feature is not properly seated and conductivematerial covers the RFID tag. This prevents the RFID reader from readingthe RFID tag. When the RFID-enabled Electrical Connector is properlyinstalled, the proper seating of the CPA feature exposes the RFID tag,allowing the RFID tag to be read by the RFID reader.

For example, the RFID tag is embedded in the housing of the plug. Thesocket has conductive material that covers the RFID tag when the plug isfully inserted into the socket. When the plug is partially retractedfrom the socket, locking the outbound tab in place, the RFID tag isexposed, allowing the RFID reader to read the RFID tag. The conductivematerial is preferably a conductive polymer, although the inventionworks with metallized plastic, as well.

The RFID tag is overmolded into the housing of the plug duringfabrication of the plug. The housing of the plug is made ofnon-conductive polymers. Alternately, the RFID tag can be printed on theplug during fabrication of the plug. Ideally, the RFID tag is placedwithin a cavity or well in the plug housing. This allows the CPA featureto better cover the RFID tag when the connector has not been properlyseated. The back of the RFID tag can be plated to prevent signal fromleaking through the plug housing and energizing the RFID tag from theback. If needed, the cavity on the plug housing containing the RFID tagcan be overmolded with conductive plastic to prevent signal from theRFID reader from reaching the RFID tag from the sides.

Alternately, to improve overall noise immunity for the RFID tag andreader system, a 5-sided box made of conductive plastic material orother conductive material can be fabricated. The RFID tag is placed inthe 5-sided shielded box. The 5-side shielded box is then placed in thecavity on the plug housing.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is illustrated with 5 drawings on 3 sheets.

FIG. 1 is a top view of a terminal plug fully inserted into a socketwith a CPA feature.

FIG. 2 is a top view of a terminal plug retracted from the socket withthe CPA feature, so that the CPA feature is fully engaged.

FIG. 3 is a perspective view of a terminal plug fully inserted into asocket with a CPA feature.

FIG. 4 is a perspective view of a terminal plug retracted from thesocket with the CPA feature, so that the CPA feature is fully engaged.

FIG. 5 is a close-up isolation view of an RFID tag embedded on aconnector housing ridge.

FIG. 6 is a front view of an alternative embodiment of a connector witha CPA with the present invention, with the socket and connector housingunattached.

FIG. 7 is a front view of an alternative embodiment of a connector witha CPA with the present invention, with the socket and connector housingattached.

DETAILED DESCRIPTION OF THE DRAWINGS

The following descriptions are not meant to limit the invention, butrather to add to the summary of invention, and illustrate the presentinvention, by offering and illustrating various embodiments of thepresent invention, an RFID-enabled Electrical Connector 1. Whileembodiments of the invention are illustrated and described, theembodiments herein do not represent all possible forms of the invention.Rather, the descriptions, illustrations, and embodiments are intended toteach and inform one skilled in the art without limiting the scope ofthe invention.

FIGS. 1-4 show the present invention, an RFID-enabled ElectricalConnector 1. FIGS. 1 and 3 show the CPA feature unlocked. FIGS. 2 and 4show the CPA feature locked. The RFID-enabled Electrical Connector 1 hasa socket 31, a connector housing 13, and a plug 14. The plug 14 isconnected directly to an electrical wire 15.

The socket 31 has a number of CPA features: a latch 11, a release 16, afirst lock indicator tabs 60, a second lock indicator tabs 50, a CPAlock tab 41, and a visual indicator 10. The socket 31 also has a matingridge 32 to accept a portion of the ridge 33 on the connector housing13. The socket 31 has a base 12 that interfaces with a circuit-board 2,or a similar electrical interface.

The connector housing 13 is mated with the plug 14. The connectorhousing 13 is then inserted into the socket 31. The direction ofinsertion is indicated 10. The connector housing 13 encountersresistance when it hits the first lock indicator tab 60, indicating thatthere is an internal locking tab that the insertion force must overcome.The connector housing 13 then encounters resistance when it hits thesecond lock indicator tab 50, indicating that there is a second internallocking tab that the insertion force must overcome. When the connectorhousing 13 is fully inserted into the socket 31, the latch is exposed11. A ridge 33 on the connector housing 13 also acts as a stop. Theridge 33 also acts as a guide that inserts in a mating ridge 32 on thesocket housing 100.

Once the connector housing 13 is fully inserted into the socket 31, thelatch must be pressed, which causes the connector housing 13 to retractslightly with respect to the socket 31. This means that the CPA features11, 16, 60, 50, 41, and 10 have been properly deployed. The connectorhousing 13 is positionally locked with respect to the socket 31 when theCPA features 11, 16, 60, 50, 41, and 10 have been properly deployed. Inthe fully inserted position, prior to the latch 11 being pressed, theconnector housing 13 is not positionally locked with respect to thesocket 31. In other words, the CPA features 11, 16, 60, 50, 41, and 10have not properly deployed. In the fully inserted position, prior to thelatch 11 being pressed, the connector housing 13 is in full electricalcontact with the socket 31, which is the state that allows the latch 11to be exposed. Of course, CPA connector systems can be accomplished withvariations of the above. The problem with current CPA connector systemsis that there is no way to assure that the CPA features 11, 16, 60, 50,41, and 10 have been properly deployed and that the connector housing 13is positionally locked with respect to the socket 31.

The present invention 1 builds on the prior art by adding an RFID tag20, which can be read by an RFID reader only when the CPA features 11,16, 60, 50, 41, and 10 have been properly deployed and that theconnector housing 13 is positionally locked with respect to the socket31. An RFID tag 20 is typically a three-dimensional right rectangle withsix sides. The RFID tag 20 is affixed in some manner to one of thecomponents of the RFID-enabled electrical connector 1. In thisembodiment, a passive RFID tag 20 is shown in FIGS. 2 and 4 as beingembedded within the connector housing 13 ridge 33. The socket housing100 is fabricated from an electrically conductive material, such as anelectrically conductive polymer. When the connector housing 31 has beenfully inserted into the socket 31, exposing the latch 11, as shown inFIGS. 1 and 3, the electrically conductive polymer of the socket housing100 shields the RFID tag 20, obscuring it from an RFID reader. In otherwords, the electrically conductive material shields the RFID tag 20 fromthe radio frequency signals of the RFID reader. FIG. 5 is an isolatedclose-up of the RFID tag 20 embedded on the ridge 33 of the connectorhousing 13. An RFID reader would be unable to energize the RFID tag 20in this position. Once the latch 11 is pressed, forcing the connectorhousing 13 to partially retract from the socket 31, the RFID tag 20 isexposed, as shown in FIGS. 2 and 4. In this state, an RFID reader wouldbe able to easily energize the RFID tag 20, and read its identifyinginformation. This would give positive confirmation that the RFID-enabledelectrical connector 1 is in its proper position, with proper electricalconnection being made.

Depending on the frequencies used by the RFID tag 20 and the fieldstrength of the RFID reader, leakage is possible. In order to preventstray leakage, potentially resulting in a false reading, the connectorhousing 13 may also be fabricated from an electrically conductivematerial, such an electrically conductive polymer. In an alternativeembodiment, the connector housing 13 can be fabricated from traditionalconnector housing polymers, and just the ridge 33 can be formed from anelectrically conductive material, such as an electrically conductivepolymer. In this embodiment, the ridge 33 formed from an electricallyconductive polymer surrounds the RFID tag 20 on five sides. Only the topsurface of the RFID tag 20 is exposed. Functionally, the RFID tag 20 isin a five-sided box constructed within the ridge 33. As a furtherembodiment to the present invention 1, the RFID tag 20 may be containedin a dedicated five-sided box fabricated from electrically conductivepolymer.

FIGS. 6 and 7 show the same invention 1 implemented on a different typeof connector with CPA. A socket 131 that inserts into a connectorhousing 113 is shown. The socket 131 has a locking tab 160, below whichis affixed an RFID tag 20. The RFID tag 20 can be affixed to the socket131 by being printed on the socket 131, being glued to the socket 131,or being embedded into the socket 131 during molding. The connectorhousing 113 is attached to a plug 114, which in turn, is connecteddirectly to an electrical wire 115. In this embodiment, the socket 131is inserted into the connector housing 113. When the socket 131 isproperly inserted into the connector housing 113, a CPA latch 111 isenabled. When the CPA latch 111 is depressed, the socket 131 andconnector housing 113 are correctly positioned and locked into place.

The connector housing 113 is made from an electrically conductivematerial, such as an electrically conductive polymer. The connectorhousing 113 has an RFID window 170. There is a void 220 in the center ofthe RFID window 170. When the socket 131 is properly seated in theconnector housing 113, and the CPA latch 111 has been depressed (compareFIG. 6 to FIG. 7), the RFID-enabled connector 1 is properly attached,and the RFID tag 20 can be read through the RFID window 170. When theCPA features of this connector have not been properly deployed, the RFIDtag will be obscured from an RFID reader by the electrically conductivematerial of the connector housing 113.

In FIG. 7, the RFID-enabled connector 1 is properly mated. The RFID tag20 attached to the socket 131 is positioned within the RFID window 170of the connector housing 131. The void 220 in the electricallyconductive material of the connector housing 113 allows the RFID tag 20to be energized and read by an RFID reader.

We claim:
 1. An RFID-enabled electrical connector comprised of a socket having a housing with deployable connector position assurance (“CPA”) features; a plug; and an RFID tag; wherein the RFID tag is obscured from being read by an RFID reader until the CPA features indicate that the CPA has been properly deployed.
 2. The RFID-enabled electrical connector of claim 1, wherein the RFID tag is passive, meaning that the RFID tag has no independent power source and the RFID tag relies on the field generated by an RFID reader in order to be energized.
 3. The RFID-enabled electrical connector of claim 2, wherein, when the CPA features have not been properly deployed, the RFID tag is obscured from being read by the RFID reader by an electrically conductive material that shields the RFID tag from the radio frequency signals of the RFID reader.
 4. The RFID-enabled electrical connector of claim 3, wherein the electrically conductive material is an electrically conductive polymer.
 5. The RFID-enabled electrical connector of claim 4, further comprising a connector housing, connected to the plug, and wherein the connector housing is capable of being inserted into the socket in such a way as to fully deploy all of the CPA features and creating an electrical connection between the plug and the socket.
 6. The RFID-enabled electrical connector of claim 5, wherein the RFID tag is affixed to the connector housing; and wherein the socket housing is fabricated from the electrically conductive polymer, resulting in the RFID tag being obscured from the RFID reader when the CPA features have not been properly deployed.
 7. The RFID-enabled electrical connector of claim 6, wherein the RFID tag is partially embedded in the connector housing.
 8. The RFID-enabled electrical connector of claim 7, wherein the RFID tag is a three-dimensional right rectangle with six sides.
 9. The RFID-enabled electrical connector of claim 8, wherein the RFID tag is embedded on five sides within the connector housing.
 10. The RFID-enabled electrical connector of claim 9, wherein the five sides of the connector housing surrounding the RFID tag are fabricated from an electrically conductive material.
 11. The RFID-enabled electrical connector of claim 10, wherein the electrically conductive material surrounding the RFID tag is an electrically conductive polymer.
 12. The RFID-enabled electrical connector of claim 11, wherein the entire connector housing is fabricated from an electrically conductive polymer.
 13. The RFID-enabled electrical connector of claim 12, wherein, when the connector housing has been fully inserted into the socket, the RFID tag is within the socket housing.
 14. The RFID-enabled electrical connector of claim 13, wherein one of the CPA features is a latch that is enabled when the connector housing is fully inserted into the socket.
 15. The RFID-enabled electrical connector of claim 14, wherein, after being enabled, depressing the latch will cause the connector housing to retract slightly from the socket, locking the connector housing into a final position with respect to the socket, and exposing the RFID tag.
 16. The RFID-enabled electrical connector of claim 4, further comprising a connector housing, connected to the plug, and wherein the socket is capable of being inserted into the connector housing in such a way as to fully deploy all of the CPA features and creating an electrical connection between the plug and the socket.
 17. The RFID-enabled electrical connector of claim 16, wherein the RFID tag is affixed to the socket; wherein the connector housing is fabricated from the electrically conductive polymer; wherein the connector housing has an RFID window in which the RFID tag is readable when the CPA features have been properly deployed; and wherein the RFID tag is obscured from the RFID reader when the CPA features have not been properly deployed, because the RFID tag is not positioned within the RIFD window.
 18. The RFID-enabled electrical connector of claim 17, wherein the RFID tag is partially embedded in the socket.
 19. The RFID-enabled electrical connector of claim 18, wherein the RFID tag is a three-dimensional right rectangle with six sides.
 20. The RFID-enabled electrical connector of claim 19, wherein the RFID tag is embedded on five sides within the socket.
 21. The RFID-enabled electrical connector of claim 20, wherein the five sides of the socket surrounding the RFID tag are fabricated from an electrically conductive material.
 22. The RFID-enabled electrical connector of claim 21, wherein the electrically conductive material surrounding the RFID tag is an electrically conductive polymer.
 23. The RFID-enabled electrical connector of claim 22, wherein the entire socket is fabricated from an electrically conductive polymer.
 24. A method of assuring the proper connection of an RFID-enabled electrical connector comprising the steps of identifying a socket with CPA features and a housing fabricated from electrically conductive plastic; inserting a connector housing with an affixed RFID tag and an attached plug into the socket; shielding the RFID tag from being read by positioning it within the electrically conductive plastic of the socket housing; pushing the connector housing into the socket until a latch, one of the CPA features of the socket, is enabled; depressing the latch to partially retract the connector housing relative to the socket; locking the connector housing into a final position with respect to the socket; exposing the RFID tag embedded in the connector housing; and reading the RFID tag embedded in the connector housing.
 25. A method of assuring the proper connection of an RFID-enabled electrical connector comprising the steps of identifying a connector housing, fabricated from an electrically conductive polymer, and having an RFID window inserting a socket with an affixed RFID tag into the connector housing; shielding the RFID tag from being read by positioning it within the electrically conductive plastic of the connector housing; pushing the socket into the connector housing until a latch, a CPA feature of the socket, is enabled; depressing the latch to correctly position the connector housing relative to the socket; locking the connector housing into a final position with respect to the socket; exposing the RFID tag in the RFID window; and reading the RFID tag embedded in the connector housing. 